A seleção adequada dos materiais e do processo de fabricação de rotores hidráulicos de turbinas Francis continua entre os maiores desafios enfrentados pelas empresas do setor desde sua criação no final do século XIX. A garantia de operação dessas máquinas está diretamente ligada à confiabilidade dos materiais, projetos e dos processos de fabricação, além da rigorosa observação de procedimentos e normas. Para que se consiga assegurar que ao final do processo de fabricação os procedimentos tenham sido respeitados, inúmeros testes são necessários. Alguns destes testes, porém podem afetar as próprias diretrizes para a execução do projeto ou fabricação. Um exemplo é o ensaio de propagação de trincas em diferentes arames de fabricação tipo GMAW e FCAW, que foi realizado com materiais cuja energia de absorção de impacto variava entre 30 e 100 J. Os resultados mostraram que o trabalho de impacto do material influencia consideravelmente a tenacidade e a velocidade de crescimento de falhas, o que consequentemente leva à conclusão de que esta propriedade define a margem de segurança do material contra propagação de trincas em aplicações como a construção de rotores hidráulicos soldados. Materiais com valores superiores de energia de impacto registraram um melhor comportamento com relação à propagação de falhas sendo mais adequados em regiões de altos esforços cíclicos, como as conexões de rotores Francis (pás x cubo x coroa). O trabalho mostra ainda quais os meios metalúrgicos e químicos necessários para se atingir um material com energia de impacto superior, demonstrando que os efeitos da ductilidade do material são mais significativos do que a resistência mecânica à tração. O que põe em xeque os padrões de dimensionamento dos componentes puramente baseados na comparação de tensões estáticas com a propriedade de resistência do material em seus limites de escoamento e ruptura. / The selection of materials and manufacturing process of hydraulic Francis Runners is one of the greatest challenges faced by sector companies since their establishment in the late 19th century. The guarantee of operation of these machines is directly linked to the reliability of the materials, designs and manufacturing processes, as well as the strict observation of procedures and standards. In order to ensure that procedures have been followed to at the end of the manufacturing process, numerous tests are required. Some of these tests, however, may affect some guidelines for project or manufacturing execution. An example is the crack propagation test on different types of manufacturing wires GMAW and FCAW, which were carried out with materials that energy of impact absorption varied from 30 to 100 J. The results showed that the impact work of the material influences considerably the tenacity and the crack growth rate, which consequently leads to the conclusion that this property defines the safety margin of the material against the cracks propagation in applications such as the construction by welding of hydraulic runners. Materials with higher values of impact energy showed a better behavior related to the failure propagation being more adequate in regions of high cyclic stresses such as the connections of Francis runners (blades x band x crown). The paper also shows the metallurgical and chemical requirements to obtain a material with higher impact energy, demonstrating that the effects of material ductility are more significant than the mechanical tensile strength. This fact challenges the current design standards of components based purely on the comparison of static tensions with the resistance property of the material at their resistance and rupture limits.

Sediment erosion is a major challenge for run-of-river power plants, especially during flood periods. Due to the high content of hard minerals such as quartz and feldspar carried in the river, substantial damage is observed on the turbine components. Material is gradually removed, thus the efficiency of the turbine decreases and the operating time of the turbine reduces. Hydro power plants situated in areas with high sediment concentration suffer under hard conditions, where turbine components could be worn out after only a short period of three months. This short life expectation causes trouble for energy production since the replacement of new turbine parts is a time consuming and costly procedure. It is desirable to design a Francis runner which will withstand sediment erosion better than the traditional designs. The literature states that an expression for erosion is velocity to the power of three. By reducing the relative velocities in the runner by 10%, the erosion will decrease almost 30%. The objective is to improve the design of a Francis turbine which operates in rivers with high sediment concentration, by looking at the design parameters in order to reduce erosion wear. A Francis turbine design tool was developed to accomplish the parameter study. In the search for an optimized Francis runner, several design proposals were compared against a reference design by evaluating the turbine’s performance. The hydraulic flow conditions and the prediction of erosion on the turbine components are simulated by analyzing the models with a Computational Fluid Dynamic (CFD) tool. A Fluid Structure Interaction (FSI) analysis ensures that the structural integrity of the design is within a desired value. Results from this research show that it is feasible to design a runner with an extended lifetime, without affecting the main dimensions and hydraulic efficiency.

Thesis (M.S.)--University of Wisconsin--Madison, 1955. / Published in Denver by the Technical Information Branch, Denver Federal Center, 1954. eContent provider-neutral record in process. Description based on print version record.

Resumo: A turbina Michell-Banki é basicamente uma máquina de ação, sendo que a característica mais importante das turbinas de ação é a não existência do tubo de sucção. A instalação do tubo de sucção numa turbina causa o aumento da queda disponível e como conseqüência, aumenta a potência gerada e a rotação da turbina. No presente trabalho propõe-se a instalação de um tubo de sucção numa turbina Michell-Banki, visando alcançar as melhorias já indicadas acima, lembrando que ao colocar o tubo de sucção aparece um grau de reação na máquina. Foi feito uma análise mecânica-hidráulica da turbina Michell-Banki proposta, com o objetivo de encontrar as equações que permitem calcular os diversos elementos da turbina. Desta maneira o trabalho apresenta uma metodologia para projeto de uma turbina Michell-Banki com tubo de sucção. Também são apresentadas as formas de traçar o rotor, o injetor e a pá diretriz. Finalmente o trabalho apresenta ainda as recomendações para a execução de projeto e construção da turbina. / Abstract: The turbine Michell-Banki is basically an action machine, and the important characteristic of the action turbines is the no existence of the suction tube. The installation of the suction tube in a turbine increases the available fall and as consequence, it increases the generated power. The rotation of the turbine is also increased by increasing the available fall. In the present work it's proposed the installation of a suction tube in a Michell-Banki turbine, aiming to reach the improvements already indicated above, remembering that when placing the suction tube a reaction degree appears in the machine. It was done an mechanical and hydraulics analysis of the Michell-Banki turbine with the objective of finding the equations that allow to calculate the several elements of the turbine proposed, and thus presenting a methodology for project of a turbine. Finally I described the way of drawing the rotor, the injector and the guideline shovel, as well as it is also recommended the process that should be followed to build the turbine. / Orientador: Luiz Roberto Carrocci / Coorientador: Paulo Magalhães Filho / Banca: Petronio Masanobu Tanisho / Banca: José Carlos Cesar Amorim / Mestre

Made available in DSpace on 2014-06-11T19:24:42Z (GMT). No. of bitstreams: 0 Previous issue date: 2004-01-30Bitstream added on 2014-06-13T18:21:00Z : No. of bitstreams: 1 alexandre_db_me_botfca.pdf: 3742670 bytes, checksum: 98e41e6dc4b4d0b4dc5de6f363be576f (MD5) / Universidade Estadual Paulista (UNESP) / O Brasil é o país que possui uma das maiores reservas mundiais de hidroenergia, em razão da quantidade imensa de rios em seu território. Em diversas áreas isoladas, tais como grupos populacionais dispersos em áreas rurais, a mais importante alternativa de produção e utilização de energia renovável é representada pelas Micro, Mini e Pequenas Centrais Hidrelétricas, que promovem oferta de energia elétrica utilizando pequenos aproveitamentos hidroenergéticos. Para pequenos aproveitamentos, o projetista de uma central hidrelétrica deve, ao definir o tipo de turbina hidráulica, fixar-se nos rotores Pelton, Francis e Kaplan e nas turbinas Banki, por serem os mais freqüentemente encontrados na prática usual. O projeto destes aproveitamentos hidroenergéticos requer muitos detalhes, regras e cálculos matemáticos que exigem tempo e conhecimento do assunto, tornando desejável uma ferramenta que forneça, de forma rápida e clara, a informação sobre os dados envolvidos no dimensionamento de equipamentos. Na sociedade moderna, tal necessidade de informação é constantemente suprida pela informática, com o uso de softwares específicos para o assunto em foco. Com esta idéia, foi desenvolvido o presente trabalho, considerando-se que a criação de um software que atende aos requisitos dos projetos de aproveitamentos hidroenergéticos executa o papel importante de ser uma ferramenta de desenvolvimento da eletrificação rural. Este trabalho pretende, especificamente para geração de energia elétrica através de pequenas centrais hidrelétricas, estabelecer um roteiro completo para pré-dimensionar turbinas hidráulicas, implementar este roteiro em sistema computacional, e criar uma interface de software de fácil uso. A partir das variáveis: vazão do rio, altura de queda do rio, e altitude local, as quais são fornecidas pelo usuário... / Brazil is the country that possesses one of the largest world reservations of hydraulic power, in reason of the immense amount of rivers in its territory. In diverse isolated areas, such as dispersed population groups in rural areas, the most important alternative of production and use of renewable energy is represented by the Micro, Mini and Small Hydroelectric Power Stations, that promote offer of electric energy using small uses hydroelectric power. For small uses, the planner of hydroelectric power plants, when defining the type of hydraulic turbine, to fix itself in the Pelton, Francis and Kaplan rotors and in the Banki turbines, for they be more frequently the found in the usual practice. The project of these uses hydroelectric power requests many details, rules and mathematical calculations that demand time and knowledge of the subject, turning desirable a tool that supplies, in a fast and simple form, the information on the data involved in the sizing of equipment. In the modern society, such need of information constantly is supplied by computer science, with the use of specific software for the subject in focus. With this idea, the present work was developed, being considered that the creation of a software that assists to the requirements of the projects of uses hydroelectric power executes the important paper of being a tool of development of the rural electrification. This work intends, specifically for generation of electric energy through small Hydroelectric Power Stations, to establish a complete guide of orientation for to make initial calculations of the dimensions of hydraulic turbines, to implement this guide of orientation in computational system, and to create an interface of software of easy use. Starting from the variables: outflow of the river, height of fall of the river, and local altitude, which is supplied by the user... (Complete abstract click electronic access below)

Orientador: Jose Geraldo Pena de Andrade / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Civil, Arquitetura e Urbanismo / Made available in DSpace on 2018-08-11T05:54:27Z (GMT). No. of bitstreams: 1 Giacomini_MarcosRoberto_D.pdf: 3148192 bytes, checksum: 975bbc84589e07811d6b2dcf58814dfe (MD5) Previous issue date: 2007 / Resumo: Este trabalho apresenta uma nova proposta para obter os parâmetros do regulador de uma turbina hidráulica, com o objetivo de melhorar o controle operacional de uma usina hidrelétrica. Dentre os diversos métodos existentes, o método de Ziegler-Nichols mostra-se adequado porque na determinação dos parâmetros do regulador efetuam-se simulações que consideram todo o comportamento hidráulico da instalação e da máquina. A partir de inúmeras simulações, para a estabilização da rotação adimensional, variando o tempo da água, o tempo da máquina e a rejeição, percebeu-se que os coeficientes utilizados no método de Ziegler-Nichols não apresentavam bons resultados em algumas situações, deixando evidente a necessidade de uma adequação. As equações propostas neste trabalho permitem a obtenção de valores mais adequados para as constantes proporcional, integral e derivativa através dos valores da constante proporcional última e do período último, como já utilizado no método de Ziegler-Nichols, em função do tempo da água, do tempo da máquina e da rejeição da potência / Abstract: This work presents a new proposal to obtain the parameters of the regulator of a hydraulic turbine, looking for the goal to increase the operational control of a hydroelectric power plant. Among many existing methods, the Ziegler-Nichols shows itself adequate because in the determination of the parameters of the regulator simulations are carried out witch consider all the hydraulic behavior of the installation and the machine. From many simulations, to the adimensional rotation stabilization, varying the water time, the machine time and the rejection, it was realized that the coefficients used in the Ziegler-Nichols method weren't presenting good results in some situations, leaving evident the needy of an adaptation. The equations suggested in this work allow obtaining more adequate values to the proportional, integral and derivative constants, through the constant last proportional values and the last period, as already used in the Ziegler-Nichols method in function of the water time, the machine time and the power rejection / Doutorado / Recursos Hidricos / Doutor em Engenharia Civil

A seleção adequada dos materiais e do processo de fabricação de rotores hidráulicos de turbinas Francis continua entre os maiores desafios enfrentados pelas empresas do setor desde sua criação no final do século XIX. A garantia de operação dessas máquinas está diretamente ligada à confiabilidade dos materiais, projetos e dos processos de fabricação, além da rigorosa observação de procedimentos e normas. Para que se consiga assegurar que ao final do processo de fabricação os procedimentos tenham sido respeitados, inúmeros testes são necessários. Alguns destes testes, porém podem afetar as próprias diretrizes para a execução do projeto ou fabricação. Um exemplo é o ensaio de propagação de trincas em diferentes arames de fabricação tipo GMAW e FCAW, que foi realizado com materiais cuja energia de absorção de impacto variava entre 30 e 100 J. Os resultados mostraram que o trabalho de impacto do material influencia consideravelmente a tenacidade e a velocidade de crescimento de falhas, o que consequentemente leva à conclusão de que esta propriedade define a margem de segurança do material contra propagação de trincas em aplicações como a construção de rotores hidráulicos soldados. Materiais com valores superiores de energia de impacto registraram um melhor comportamento com relação à propagação de falhas sendo mais adequados em regiões de altos esforços cíclicos, como as conexões de rotores Francis (pás x cubo x coroa). O trabalho mostra ainda quais os meios metalúrgicos e químicos necessários para se atingir um material com energia de impacto superior, demonstrando que os efeitos da ductilidade do material são mais significativos do que a resistência mecânica à tração. O que põe em xeque os padrões de dimensionamento dos componentes puramente baseados na comparação de tensões estáticas com a propriedade de resistência do material em seus limites de escoamento e ruptura. / The selection of materials and manufacturing process of hydraulic Francis Runners is one of the greatest challenges faced by sector companies since their establishment in the late 19th century. The guarantee of operation of these machines is directly linked to the reliability of the materials, designs and manufacturing processes, as well as the strict observation of procedures and standards. In order to ensure that procedures have been followed to at the end of the manufacturing process, numerous tests are required. Some of these tests, however, may affect some guidelines for project or manufacturing execution. An example is the crack propagation test on different types of manufacturing wires GMAW and FCAW, which were carried out with materials that energy of impact absorption varied from 30 to 100 J. The results showed that the impact work of the material influences considerably the tenacity and the crack growth rate, which consequently leads to the conclusion that this property defines the safety margin of the material against the cracks propagation in applications such as the construction by welding of hydraulic runners. Materials with higher values of impact energy showed a better behavior related to the failure propagation being more adequate in regions of high cyclic stresses such as the connections of Francis runners (blades x band x crown). The paper also shows the metallurgical and chemical requirements to obtain a material with higher impact energy, demonstrating that the effects of material ductility are more significant than the mechanical tensile strength. This fact challenges the current design standards of components based purely on the comparison of static tensions with the resistance property of the material at their resistance and rupture limits.

M.S.

The use of draft tubes with annular injection was investigated with respect to low-head applications. A numerical model was developed and refined to fit the data from two laboratory test models. The latter model was a laboratory scale hydropower system which demonstrated 20-31 per cent head augmentation under various conditions. The numerical model was used to generate performance maps of full scale, low-head systems in the range from 200 to 500 kW. The performance maps were then used in a system modeling program to evaluate the system performance, cost and cavitation characteristics. The draft tube ejector system was found to reduce the system cost/kW by 2-10 per cent when compared to a conventional system with the same gross head and total flow rate. This was accomplished by using smaller, less expensive turbines which utilize excess flow in draft tube ejectors to increase the effective head across the turbine. The resulting reduction in system cost was found to exceed the corresponding reduction in capacity. The use of draft tube ejectors was found to require slightly lower turbine settings due to increased cavitation risk. / Master of Science

L’énergie hydraulique, où l’énergie cinétique de l’eau est transformée en énergie électrique, représente une contribution importante aux énergies renouvelables. L’eau qui passe par les turbines hydrauliques contient toujours une partie solide, par exemple du sable et de l’argile. Ces sédiments peuvent atteindre des niveaux de concentration élevés, ce qui nuit considérablement à la structure de la turbine par un mécanisme d’endommagement appelé érosion hydro-abrasive. Des types de turbine impliquant des vitesses d’écoulement très élevées, comme les turbines Pelton, sont particulièrement sensibles à l’érosion hydro-abrasive. Les simulations numériques présentent un moyen efficace d’étudier le sujet de l’érosion hydro-abrasive dans les turbines Pelton car elles permettent facilement la variation des nombreux paramètres. Ainsi, une réponse immédiate aux questions opérationnelles, de conception ou d’optimisation peut être obtenue. Cependant, il a été démontré que l’application des modèles d’érosion généraux et souvent utilisés ne fournit pas de résultats corrects en raison des propriétés particulières du matériel et de l’écoulement des turbines Pelton. Par conséquent, ce travail étudie le potentiel de la modélisation de l’érosion directe basée sur des principes fondamentaux. Cela implique que le mouvement des sédiments dans le fluide est simulé, leurs paramètres au moment de l’impact enregistrés et ensuite l’endommagement macroscopique global du matériel calculé sur la base des simulations de structure en microéchelle. Une formulation très appropriée pour les simulations fluides dans les turbines Pelton est une méthode sans maillage, plutôt nouvelle, qui s’appelle Smoothed Particle Hydrodynamics (SPH). Par conséquent, la première partie de ce travail aborde la mise en oeuvre et l’évaluation d’un modèle Lagrangien de transport des sédiments dans le cadre de cette méthode où les sédiments sont transportés par une équation de mouvement. L’effet du bruit inhérent à la méthode SPH sur le mouvement des sédiments est évalué par rapport à l’effet de la dispersion turbulente des sédiments, qui a été introduite par un modèle basé sur l’équation de Langevin. En outre, les termes liés aux différentes forces dans l’équation du mouvement sont étudiés dans le cadre de la méthode SPH. Une deuxième partie de ce travail développe une approche efficace et généralement applicable pour obtenir l’endommagement globale sans adopter des modèles d’érosion. Pour obtenir cet endommagement global en macroéchelle, l’endommagement causé par un seul impact de sédiment, qui est calculé par des simulations de structure en microéchelle, est combiné avec les statistiques d’impact des simulations du fluide. / Hydraulic energy represents one important contribution to the growing source of renewable energies where the kinetic energy of water is transformed into electric energy. The water flowing through the hydraulic turbines always contains a solid part, for example sand and clay. Those sediments can reach high concentrations, harming importantly the turbine structure by a mechanism called hydro-abrasive erosion. Turbine types implying very high flow velocities, like Pelton turbines, are in particular sensitive to hydro-abrasive erosion. Numerical simulations present an efficient way to study the topic of hydro-abrasive erosion in Pelton turbines as they allow the variation of numerous parameters. Thus an immediate response to operational, design or optimization questions can be obtained. However it has been shown that the application of general, widely used erosion models do not deliver physical correct results due to the particular material and flow properties of Pelton turbines. Consequently this work investigates the potential of erosion modeling based on first principals. That means the sediment movement in the fluid is simulated, their state at impact tracked and then the overall macroscopic material damage calculated based on microscale structural simulations. A convenient formulation for fluid simulations in Pelton turbines is the rather novel, meshless method Smoothed Particle Hydrodynamics (SPH). Therefore the first part of this work addresses the implementation and evaluation of a Lagrangian sediment transport model in the framework of this method where sediments are transported by a particle equation of motion. The effect of the SPH method inherent noise on the sediment movement is evaluated against the effect of the turbulent dispersion of the sediments, which has been introduced via an ad-hoc model based on the Langevin equation. Furthermore the different force terms in the particle equation of motion are investigated with respect to the SPH method. A second part develops an efficient and general applicable approach to obtain the overall erosion damage without adopting erosion models. Therefore the damage caused by a single sediment impact is calculated by structural simulations on the microscale in a first step. In a second step that isolated damage is combined with impact statistics from the fluid simulations and hence gives the overall damage profile on the macroscale.